Support grid and alignment appartus for a filter element and housing

ABSTRACT

An improved air filter element is provided with an anti-crown support grid on a clean side of the filter media. The support grid includes one or more elongated mounting members provided along periphery portions of the grid and at least one support rib spanning between and secured at opposing ends to the mounting members. The mounting members are embedded within a peripheral seal frame. The support grid may include at least one alignment feature sized, configured and positioned to be receivable into a complimentary feature of a housing so as to positionally lock the filter element and the housing.

CROSS REFERENCE TO RELATED APPLICATIONS

The present application is a Continuation in Part (CIP) of currentlypending U.S. Utility patent application Ser. No. 12/405,342 filed Mar.17, 2009, the contents of which are incorporated herein by reference inits entirety and to the fullest extent of the law.

TECHNICAL FIELD

The present invention relates to vehicle engine air intake systems andair filters for such systems and, more particularly, to air filtersprovided with media reinforcing elements.

BACKGROUND OF THE INVENTION

Internal combustion engines require a source of combustion air. Atypical source for combustion air is air drawn from outside of thevehicle, which commonly includes particulate contaminants. An aircleaner including an air filter element is normally provided in the airinduction system to capture these particulate contaminants beforecombustion air is delivered to the vehicle engine.

Air filters include filter media having relatively small pores for airflow therethrough that operate to inhibit the passage of undesiredparticulate contaminants. Since the presence of a filter media in theintake air stream acts to restrict air flow, air flow through the filterelement necessarily produces a pressure differential or pressure dropbetween the filter element inlet and outlet surfaces (i.e. across thefilter media). This air flow induced pressure drop produces deflectionforces in the filter media of the filter element. These deflectionforces are aligned with the air flow direction and, (for example) inpanel type air filters, the deflection forces are typically normal toplane defined by the filter element media. The deflection forces tend todistort, deflect or “crown” the filter element.

Air filter elements are often made of pleated filter paper media securedto a periphery support frame, such as a molded plastic or elastomericframe. Pleating the filter paper media increases the available filtersurface area, while the pleats additionally serve to reinforce thefilter media of the filter element against deformation or deflection dueto air flow induced forces. In normal operating conditions this isusually sufficient.

Operation of the engine and its associated induction air filter in anadverse climate can substantially increase deflection force loading onthe media of the filter element. In cold climates the air filter candraw in snow and ice pellets. The drawn-in snow is blocked by the filterelement, accumulates at the dirty side of the filter element and acts tofurther block air flow through the filter element thereby increasing thepressure drop across the filter element together with an increase indeflection forces acting upon the filter media. Similarly, somevarieties of filter media, such as types of filter paper, are prone toabsorbing water droplets from the intake air stream, for example ifoperated in rainy or dense fog conditions. Water wets the filter media,obstructs pores in the media and may act to further obstruct air flowthrough the media with the resultant further increase in pressure dropand resultant deflection forces.

As can be seen, there is a need for an improved air filter element thatprovides improved resistance to filter media deformation without undulyincreasing filter element cost or complexity.

SUMMARY OF THE INVENTION

In one aspect of the invention, an improved air filter assembly or aircleaner includes an air filter element having at least one filter media,a peripheral seal frame extending circumferentially about and secured toperiphery edges of the filter media and an anti-crown support gridpositioned at a clean side of the filter media. The support gridincludes at least one side rail provided along circumferential peripheryportions of the support grid. At least one support rib is providedspanning between and secured at opposing ends to the side rails. Aplurality of frame attachment members are spaced along, secured to andextend outwardly from the support rails. The attachment members areconfigured and adapted to be moldably embedded into the seal frame tosecure the support grid to the seal frame. At least one alignmentfeature is provided along at least one of the side rails. The alignmentfeature is sized, configured and positioned to be receivable into acomplimentary feature of the housing to lock the relative positions ofthe housing and the filter element.

In another aspect of the invention, the alignment feature is or includesan elongated alignment rib spanning across an interior of the supportgrid and secured at opposing ends to the side rails. The elongatedalignment rib projecting outwards in at least one portion from a planein which the support grid generally lies.

In another aspect of the invention, the alignment feature includes atleast one alignment tab secured to the side rails and projectingoutwards from a plane in which the support grid generally lies.

In another aspect of the invention, the filter media is a pleated filtermedia and the support ribs are positioned to have an angular alignmentdifferent from an angular alignment of the pleats.

In another aspect of the invention, a first group of support ribs and asecond group of support ribs are provided. Support ribs in the first ribgroup are aligned in a first direction and positioned in a spacedparallel fashion to each other. Support ribs in the second rib group arealigned in a second direction and position in a spaced parallel fashionrelative to each other. The first and the second directions are chosensuch that an angle between the first and second directions is between 10and 90 degrees.

In another aspect of the invention, the support ribs are sized andspaced such that air flow spaces between the support ribs has anaccumulated area of at least 95% of the area enclosed by the seal frame.

In another aspect of the invention, the housing includes a first housingportion and a mateable second housing portion. The housing portions areconfigured to receive and close about the air filter element. The firsthousing portion includes an alignment receptor having a concave receptorsized and configured to receive a portion of the alignment feature so asto lock alignment of the filter element with the first housing portion.

In another aspect of the invention, an improved air filter assemblyincludes an air filter element having at least one filter media having aplurality of spaced folds forming zigzag pleats in said filter media. Aperipheral elastomeric seal frame extends circumferentially about and issecured onto periphery edges of the filter media. A substantially planaranti-crown support grid is arranged at and extends across a clean sideface of the filter media. The support grid includes at least oneelongated mounting member arranged proximate to outer edges of theanti-crown support grid with the mount members each aligned parallel tothe plane of the anti-crown support grid. The elongated mounting membersare aligned with and embedded within the seal frame. A first support ribgroup includes at least one elongated support rib extending parallel topleat folds and spanning across the clean side face with the ribs eachsecurely affixed at opposing ends to said at least one elongatedmounting members. A second support rib group includes at least oneelongated support rib abutting against and extending across multiplepleat folds at the clean side face, with the ribs of the second supportrib group each securely affixed at opposing ends to at least oneelongated mounting member. The ribs of said second support rib groupspan across and connect to at least a portion of the ribs of said firstsupport rib group.

The above features and advantages and other features and advantages ofthe present invention are readily apparent from the following detaileddescription of the best modes for carrying out the invention when takenin connection with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying Figures, where like reference numerals refer toidentical or functionally similar elements throughout the separate viewsand which together with the detailed description below are incorporatedin and form part of the specification, serve to further illustratevarious embodiments and to explain various principles and advantages allin accordance with the present invention.

Features of the present invention, which are believed to be novel, areset forth in the drawings and more particularly in the appended claims.The invention, together with the further objects and advantages thereofmay be best understood with reference to the following description,taken in conjunction with the accompanying drawings. The drawings show aform of the invention that is presently preferred; however, theinvention is not limited to the precise arrangement shown in thedrawings.

FIG. 1A is a plan view of the clean side of an air filter elementequipped with the anti-crown support grid, consistent with the presentinvention;

FIG. 1B is a plan view of one embodiment of the anti-crown support grid,viewed from the side facing the filter media, consistent with thepresent invention;

FIG. 1C is an enlarged view of a portion of the support grid of FIG. 1B,consistent with the present invention;

FIG. 1D is an enlarged view of a portion of another embodiment of thesupport grid, consistent with the present invention;

FIG. 2A is a perspective view of an air cleaner housing cover depictingone embodiment of a grid alignment feature, consistent with the presentinvention;

FIG. 2B is an enlarged view of the grid alignment feature of FIG. 2A,consistent with the present invention;

FIGS. 3A-3D are partial sectional views of an air cleaner housing andfilter element incorporating features of the present invention andillustrating operation of the filter alignment features;

FIG. 4A is an exploded perspective assembly view of the anotherembodiment of the anti-crown support grid, consistent with the presentinvention;

FIG. 4B is a perspective view of the embodiment of FIG. 4A showing theanti-crown support grid embedded into the peripheral seal frame,consistent with the present invention; and

FIG. 4C is an assembled perspective view of the embodiment of FIG. 4A.

Skilled artisans will appreciate that elements in the Figures areillustrated for simplicity and clarity and have not necessarily beendrawn to scale. For example, the dimensions of some of the elements inthe Figures may be exaggerated relative to other elements to help toimprove understanding of embodiments of the present invention.

DESCRIPTION OF THE PREFERRED EMBODIMENTS

Before describing in detail embodiments that are in accordance with thepresent invention, it should be observed that the embodiments resideprimarily in combinations of method steps and apparatus componentsrelated to an apparatus and method for a support grid for a filterelement and alignment features and means. Accordingly, the apparatuscomponents have been represented where appropriate by conventionalsymbols in the drawings, showing only those specific details that arepertinent to understanding the embodiments of the present invention soas not to obscure the disclosure with details that will be readilyapparent to those of ordinary skill in the art having the benefit of thedescription herein.

In this document, relational terms such as first and second, top andbottom, and the like may be used solely to distinguish one entity oraction from another entity or action without necessarily requiring orimplying any actual such relationship or order between such entities oractions. The terms “comprises,” “comprising,” or any other variationthereof, are intended to cover a non-exclusive inclusion, such that aprocess, method, article, or apparatus that comprises a list of elementsdoes not include only those elements but may include other elements notexpressly listed or inherent to such process, method, article, orapparatus. An element proceeded by “comprises . . . a” does not, withoutmore constraints, preclude the existence of additional identicalelements in the process, method, article, or apparatus that comprisesthe element.

The present invention generally relates to an improved air filterelement incorporating an anti-crown support grid that is molded into theseal frame of the filter element as well as an air cleaner housingequipped with complimentary alignment features. The support gridprovides mechanical support to the filter media to strengthen the filerelement media from distorting or “crowning” under the influence of airflow induced forces. The support grid may be further reinforced bymating features provided in the air cleaner housing that supportivelymate with the alignment features that may be provided on the supportgrid. In the event of snow pack accumulation or other obstruction of theair filter media, the invention provides increased resistance tocrowning or distortion of the filter media, therefore reducing thechance of a mechanical failure of the filter element.

FIG. 1A presents plan view of the clean side (air outlet side) of animproved air filter element 10 advantageously equipped with theanti-crown support grid 12, consistent with the present invention. Airfilter element 10 includes a peripheral seal frame 18 extendingcircumferentially about the periphery edges of the pleated filter media14. Other types of filter media than pleated filter media may also beused without deviating from the inventive disclosure herein. The pleatedfilter media 14 is supportively and sealably secured along its edges tothe peripheral seal frame 18 such that air is not permitted to flowbetween the pleated filter media 14 and the peripheral seal frame 18.

FIG. 1B presents a plan view of one embodiment of the anti-crown supportgrid 12 as viewed from the side normally facing the filter media 14,consistent with the present invention. FIG. 1C provides an enlarged viewof a portion of the support grid 12 of FIG. 1B, consistent with thepresent invention. The anti-crown support grid 12 is closed aboutperiphery side portions by side rails 20. Spaced along, secured to andextending outwardly from the side rails 20 are a plurality of frameattachment members 22. Frame attachment members 22 are configured to beembedded by a molding process into portions of the peripheral seal frameso as to secure the anti-crown support grid 12 onto the peripheral sealframe 18 in position against the clean side 24 of the filter media 14.The seal frame member includes an elastomeric seal material. A pluralityof support ribs 26 extend across the opening between the side rails 20and are secured at their opposing ends to the side rails 20 so as toform a support grid structure configured to support the filter media 14and to actively resist deflection forces F induced into the filter media14 such as due to air flow through the filter media.

The anti-crown support grid is preferably formed of a structurallystable, tensile elongation resistant thermoplastic material, althoughthe support grid may alternately be made of metallic materials such asaluminum or steel. The support ribs have a first rib group that ispreferably aligned in a first direction 28 and a second rib group thatis preferably aligned in a second direction 30 substantially normal (θis approximately 90 degrees) relative to the first direction 28. Theinvention does not require the second direction 30 to be normal to thefirst direction 28. It is envisioned that instead θ may be any angle of10 degrees to 90 degrees, with larger angles in the range preferred.

If the filter media 14 is a pleated filter media, it is preferred thatthe first direction 28 and second direction 30 be chosen such that thesupport ribs 26 do not directionally align with the direction of thepleats 16 so that the support ribs always supportively bridge acrossridges of the pleats 16 rather than to fall within gaps or valleysbetween the pleats 16.

To prevent unintended obstruction of air flow through the filter element10, it is preferred that the support ribs are sized and spaced such thatthe air flow spaces 32 between the support ribs 26 have an area at least95% of the area enclosed by the peripheral seal frame 18.

At least one alignment feature is provided along at least one side rail20 of the anti-crown support grid 12. It is preferred that the alignmentfeature be provided as at least one elongated alignment rib 34 spanningacross the interior of the support grid 12 and secured at opposing endsto side rails 20 of the support grid 12. It is further preferred thatthe elongated alignment rib be configured with a substantially largercross section relative to the support ribs so as to provide increasedresistance to bending or flexing of the support grid under load. It isstill further preferred that the elongated alignment ribs be spacedapart in a parallel arrangement so as to divide the span length of eachpleat into substantially equal lengths defined between adjacentalignment ribs or an alignment rib and a side rail.

FIG. 1C, in particular, shows one embodiment of an anti-crown supportgrid 12 in which the alignment feature is realized with an elongatedalignment rib 34 having a sufficient cross section configured to resistflexure so as to provide additional support to filter media 14.

FIG. 1D depicts an enlarged view of another embodiment of an anti-crownsupport grid 12A in which the alignment feature is alternately realizedas an alignment tab 38. At least one alignment tab 38 is provided, eachalignment tab 38 is secured to a side rail 20 and configured to projectoutwards from a plane P in which the anti-crown support grid 12 or 12Agenerally lies. The alignment tab 38 is configured to provide the samefilter element alignment function (described later below) as provided bythe elongated alignment rib 34, but lacking the alignment rib's abilityto provide enhanced resistance to bending of the support ribs 26 underload, therefore it may provide less support to the filter media 14 inresisting deformation or deflection due to the action of deflectiveforces F.

FIG. 2A provides a perspective view of the interior of a first aircleaner housing portion 42 provided with an embodiment of a gridalignment receptor 40, consistent with the present invention. FIG. 2B isan enlarged view of the alignment receptor 40 of FIG. 2A, consistentwith the present invention. The first air cleaner housing portion 42may, in some embodiments, be an air cleaner cover while in otherembodiments it may be an air cleaner housing base. In any case, thealignment receptor 40, according to the present invention, is typicallyprovided in the air cleaner housing portion that faces the clean side 24of the air filter element 10. The alignment receptor 40 includes aconcave receptacle 44 which in some embodiments may include a concavecircular arc portion 46 extended at opposing ends by blended curves 48.The blended curves 48 are configured to smoothly guide the filterelement alignment features (such as alignment tab 36 or elongatedalignment rib 34) into the concave circular arc portion 46 of thealignment receptor so as to lock alignment of the filter element 10 withthe first air cleaner housing portion 42.

FIGS. 3A-3D provide partial sectional views of the interior of an aircleaner housing 50 and installed filter element 10 incorporatingfeatures of the present invention. FIGS. 3A-3D illustrate theinteraction between the alignment receptor 40 and one possibleembodiment of the alignment feature (illustrated embodiment is theelongated alignment rib 34) during closure of the air cleaner housing50. Only a portion of the sidewalls of the air cleaner housing 50 areshown to provide a clearer view of the integration between the alignmentfeature and alignment receptor. The air cleaner housing 50 has a secondair cleaner housing portion 52 configured to receive air filter element10. The air cleaner housing 50 includes a first air cleaner housingportion 42 which is configured to close over the filter element 10 andmate with either or both the peripheral seal frame 18 of the filterelement and sidewalls of the second air cleaner housing portion 52 so asto provide a substantially dust tight and air tight seal between the aircleaner housing portions 42, 52 and the filter element 10.

Some embodiments of air cleaner housings may include partially hingeabletab and slot features 54. In FIG. 3A the first air cleaner housingportion 42 includes a partially hingable tab feature configured to bereceived into a slot feature of the second air cleaner housing portion52. When assembling the first air cleaner housing portion 52 onto thesecond air cleaner housing portion 52, the tab is first inserted intothe slot feature to partially hingeably secure the first housing portion42 to the second housing portion 52. Once secured, the first housingportion may be rotated about a hinge axis 56 to move the first aircleaner housing portion 42 towards a closed position with the second aircleaner housing portion 52 as shown by arrow 58. As illustrated in FIG.3A, the clean side 24 of the filter element 10 with the anti-crownsupport grid 12 including the elongated alignment rib 34 faces the firstair cleaner housing portion 42.

Referring now to FIG. 3B, it may be that while the first air cleanerhousing portion 42 is closing onto the second air cleaner housingportion 52, that a misalignment is present between the first air cleanerhousing portion 42 and the filter element 10. A potential misalignedcondition is shown in FIG. 3B in which a portion of the elongatedalignment rib 34 contacts a blended curve 48 portion (see FIG. 2B) ofthe alignment receptor 40 rather than being received into the concavecircular arc portion 46 of the alignment receptor 40. As discussedearlier, the alignment receptor 40 includes a blended curve 48advantageously shaped and configured to ultimately guide the alignmentfeatures (in the illustrated embodiment the elongated alignment rib 34)into the concave circular arc portion 46 of the alignment receptor 40.One way to accomplish this is for the first air cleaner housing portion42 to slide relative to the second air cleaner housing portion 52; thismovement is permitted by the partially rotatable tab and slot feature 54as the tab is free to slide within the slot. Such tab and slot featuresare common attachment means used in the art. As the first air cleanerhousing portion 42 is urged by the interaction of the elongatedalignment rib 34 in the alignment receptor 40, the first air cleanerhousing portion 42 is repositioned for successful sealable closure ontothe filter element 10 and second air cleaner housing portion 52, asshown in FIGS. 3C and 3D.

Referring again to FIG. 2A. The first air cleaner housing portion 42 mayadvantageously include a seal ledge 60 configured to supportivelycontact the side rails 20 of the anti-crown alignment grid 12 when theair cleaner housing 50 is in a fully closed position (positionillustrated in FIGS. 3C and 3D). The seal ledge 60 as well as thealignment receptor 40 are then operable to support the anti-crownsupport grid 12 and its filter media 14 by transferring air flow induceddeflection forces F (see FIG. 1A) onto the first air cleaner housingportion 42.

The discussion now turns to FIGS. 4A through 4C. In FIGS. 4A through 4Clike components to those discussed in FIGS. 1A through 1D are identifiedwith numeric references incremented by 100.

Referring now to FIGS. 4A-4C. FIG. 4A presents an exploded perspectiveassembly view of the another embodiment of the anti-crown support grid112 of FIGS. 1A through 1D. Components are depicted in an exploded viewfor easier understanding of the structure of each component. FIG. 4B isa perspective view of the embodiment of FIG. 4A showing the anti-crownsupport grid 112 embedded into the peripheral seal frame 118 and shownwithout the filer media 114 for clarity. FIG. 4C is a fully assembledperspective view of the embodiment of FIG. 4A depicting the unitaryone-piece replaceable filter element 110.

The air filter element 110 includes one or more sheets of filter media114 which are folded into spaced parallel folds to form a zigzag pleatedfilter media sheet 114. The filter media 114 has a clean side 124visible in FIG. 4A and an opposing dirty side 164. Airflow flows throughthe filter media 114 from the dirty side 123 to the clean side 164.Airflow through the filter media 114 results in deflection forces actingupon the filter media due to the pressure drop developed across thefilter media, as discussed earlier with FIG. 1A. As discussed earlier,the anti-crown support grid 112 provides mechanical support to thefilter media 114 to strengthen the filer element media 114 fromdistorting or “crowning” under the influence of air flow induced forces“F” (see FIG. 1A).

A substantially planar anti-crown support grid 112 is arranged at andextends across the clean side face 124 of the filter media 114. Theanti-crown support grid 112 is shown with elongated mounting members 172arranged at the outer edges of the anti-crown support grid 112. Theelongated mounting members 172 are depicted as connected end to end toform a continuous boundary encircling the anti-crown support grid 112,although in other embodiments the elongated mounting members 172 may notbe connected end to end and may be spaced apart from each other.

The mount members 166 are each aligned parallel to the plane of theanti-crown support grid 112. The elongated mounting members 166 arepositioned and aligned so as to be embedded within and hidden within theelastomeric seal frame 118 of the filter element 110. The anti-crownsupport grid 112 includes a first support rib group 168 of elongatedsupport ribs extending parallel to the pleat folds 174 of the filtermedia 114 and spanning across the clean side face 124 of the filtermedia 114. The support ribs of the first support rib group 170 are eachsecurely affixed at opposing ends to the elongated mounting members 172circumferentially surrounding the substantially planar anti-crownsupport grid 112. A second support rib group 170 includes a plurality ofspaced elongated support ribs which are arranged to abut against andextend across the multiple pleat folds 174 at the clean side face 124with the ribs of the second support rib group 170 each securely affixedat opposing ends of each rib to the elongated mounting members 166. Theribs of the second support rib group 170 spans across and preferably arefixedly secured to the ribs of said first support rib group 168providing a rigid frame structure to support the filter media 114against crowning or deflection. The anti-crown support grid 112 ispreferably formed of a structurally stable, tensile elongation resistantthermoplastic material, although the support grid may alternately bemade of metallic materials such as aluminum or steel.

As discussed earlier the peripheral seal frame 118 extendscircumferentially about and is secured onto the peripheral edges of thefilter media 114. The substantially planar anti-crown support grid 112is embedded into the peripheral seal frame 118 such that the peripheralseal frame 118 with the anti-crown support grid 112 and the filter media114 are embodied as a single piece unitary filter element 110 which isinstalled and replaced as a single component.

The elongated support ribs in the first support rib group 168 areelongated in a first direction and positioned in a spaced parallelfashion relative to each other on the clean side face 124 of the filermedia 114. The support ribs in the second support rib group 170 areelongated in a second direction and positioned in a spaced parallelfashion relative to each other on the clean side face 124 of the filtermedia 114. The first and said second directions are chosen such that anangle between said first and second directions is between 10 and 90degrees. Preferably the support ribs in the first support rib group 168are arranged perpendicular to the elongated ribs in the second supportrib group 170. This is preferred but not required.

The substantially planar anti-crown support grid 112 may be providedwith one or more alignment features, for example the elongated alignmentrib 34 discussed earlier with FIG. 1A or the alignment tabs 38 of FIG.1D. The alignment features, when present, are secured and affixed ontothe elongated mounting members 172 (which in this embodiment replacesthe side rails 20 of FIGS. 1A through 1D). The function of the alignmentfeatures in positioning and aligning the filter element within thefilter housing were discussed earlier with FIGS. 2A-3D, this earlierdisclosure applies to the embodiment of FIGS. 4A-4C also and is notrepeated here. The alignment features (34 or 38) are secured affixed tothe mounting member(s) with the alignment features sized, configured andpositioned to be received into a grid alignment receptor (40, FIG. 2A)of the filter housing (42, FIG. 2A), as discussed earlier.

To minimize restriction of the air flow through the filter element 110,the support ribs of the second support rib group 170 may be alignedparallel to and may lie directly upon the glue beads 162 provided on theclear air face 124 of the filter media 114. The glue beads 162 may beprovided to lock or maintain spacing between adjacent pleats of thefilter media 114 so as to provide uniform pleat spacing and preventpleats from bunching or otherwise restriction airflow.

Features of a suitable filter housing were discussed earlier with FIGS.2A through 3D and are not repeated with this embodiment.

In the foregoing specification, specific embodiments of the presentinvention have been described. However, one of ordinary skill in the artappreciates that various modifications and changes can be made withoutdeparting from the scope of the present invention as set forth in theclaims below. Accordingly, the specification and figures are to beregarded in an illustrative rather than a restrictive sense, and allsuch modifications are intended to be included within the scope ofpresent invention. The benefits, advantages, solutions to problems, andany element(s) that may cause any benefit, advantage, or solution tooccur or become more pronounced are not to be construed as a critical,required, or essential features or elements of any or all the claims.The invention is defined solely by the appended claims including anyamendments made during the pendency of this application and allequivalents of those claims as issued.

1. An improved air filter assembly comprising: an air filter element including at least one filter media having a plurality of spaced folds forming zigzag pleats in said filter media, said pleated filter media having a clean side face and an opposing dirty side face; a peripheral seal frame extending circumferentially about and secured to periphery edges of said filter media, said seal frame including elastomeric material; a substantially planar anti-crown support grid arranged at and extending across a clean side face of said filter media, said support grid including: at least one elongated mounting member arranged proximate to outer edges of said anti-crown support grid, said at least one mounting member each aligned parallel to said plane of said anti-crown support grid, said elongated mounting members aligned with and embedded within said seal frame; a first support rib group comprising at least one elongated support rib extending parallel to pleat folds and spanning across said clean side face, said ribs of said first support rib group each securely affixed at opposing ends to said at least one elongated mounting member; a second support rib group comprising at least one elongated support rib abutting against and extending across multiple pleat folds at said clean side face, said ribs of said second support rib group each securely affixed at opposing ends to said at least one elongated mounting members, wherein ribs of said second support rib group span across and connect to at least a portion of said ribs of said first support rib group.
 2. The improved air filter assembly according to claim 1, wherein said support ribs in said first support rib group are aligned in a first direction and positioned in a spaced parallel fashion relative to each other, wherein support ribs in said second support rib group are aligned in a second direction and positioned in a spaced parallel fashion relative to each other; and wherein said first and said second directions are chosen such that an angle between said first and second directions is between 10 and 90 degrees.
 3. The improved air filter assembly according to claim 2, wherein said first rib group is aligned substantially perpendicular to said second rib group.
 4. The improved air filter assembly according to claim 1, wherein at least one alignment feature provided along at least one of said at least one mounting members, said alignment feature is sized, configured and positioned to be receivable into a complimentary feature of a housing.
 5. The improved air filter assembly of claim 3, wherein said support ribs are sized and spaced such that open air flow spaces between said support ribs has an accumulated area of at least 95% of an area enclosed by said seal frame.
 6. The improved air filter assembly according to claim 3, wherein said pleated filter media includes glue beads affixed onto, extending across and supportively interconnecting adjacent pleat folds of the filter media, said glue beads maintaining spacing of a said spaced folds, wherein a portion of said ribs of said second support rib group are aligned parallel to and line directly on respective ones of said glue beads.
 7. The improved air filter assembly according to claim 6, wherein at least one alignment feature provided along at least one of said at least one mounting members, said alignment feature is sized, configured and positioned to be receivable into a complimentary feature of a housing.
 8. The improved air filter assembly according to claim 1, wherein said elongated mounting members are affixed to each other end to end forming a continuous frame circumferentially surrounding outer edges of said anti-crown support grid.
 9. The improved air filter assembly according to claim 1, wherein wherein said elongated mounting members are completely embedded within and hidden within said seal frame.
 10. The improved air filter assembly according to claim 4, wherein said at least one alignment feature comprises an elongated alignment rib spanning across the clean air face of the filter media and affixed proximate to its opposing ends to said at least one elongated mounting members, said elongated alignment rib having a substantially larger cross section relative to said support ribs.
 11. An air filter assembly comprising: an air filter element including at least one filter media having a plurality of spaced folds forming zigzag pleats in said filter media, said pleated filter media having a clean side face and an opposing dirty side face; a peripheral seal frame extending circumferentially about and secured to periphery edges of said filter media, said seal frame including elastomeric material; a substantially planar anti-crown support grid arranged at and extending across a clean side face of said filter media, said support grid including: at least one elongated mounting member arranged proximate to outer edges of said anti-crown support grid, said at least one mounting member each aligned parallel to said plane of said anti-crown support grid, said elongated mounting members aligned with and embedded within said seal frame; a first support rib group comprising at least one elongated support rib extending parallel to pleat folds and spanning across said clean side face, said ribs of said first support rib set each securely affixed at opposing ends to said at least one elongated mounting member; a second support rib group comprising at least one elongated support rib abutting against and extending across multiple pleat folds at said clean side face, said ribs of said second support rib group each securely affixed at opposing ends to said at least one elongated mounting member, wherein ribs of said second support rib group span across and connect to at least a portion of said ribs of said first support rib group. wherein said support ribs in said first support rib group are aligned in a first direction and positioned in a spaced parallel fashion relative to each other, wherein support ribs in said second support rib group are aligned in a second direction and position in a spaced parallel fashion relative to each other, wherein said first and said second directions are chosen such that an angle between said first and second directions is between 10 and 90 degrees, wherein said support ribs are sized and spaced such that air flow spaces between said support ribs has an accumulated area of at least 95% of an area enclosed by said seal frame, wherein said elongated mounting members are completely embedded within and hidden within said seal frame; and a housing comprising: a first housing portion; and a second housing portion configured to closeably mate with said first housing portion, said housing portions configured to receive and close about said air filter element.
 12. The air filter assembly according to claim 11, wherein at least one alignment feature is provided and securely affixed to at least one of said at least one mounting members, and wherein said first housing portion includes at least one alignment receptor formed into said housing, each alignment receptor having a concave receptor member receiving and engaging a respective one of said at least one alignment feature, said engagement locking position and alignment of said filter element with respect to said first housing portion. 